Matronics Email Lists :: View topic - Trimming Acrylic Windshield

Matronics Email Lists
Web Forum Interface to the Matronics Email Lists

Get Email Distribution Too! FAQ Search Memberlist Usergroups Register

Profile Log in to check your private messages Log in

Trimming Acrylic Windshield
Goto page 1, 2 Next

Matronics Email Lists Forum Index -> Kitfox-List

View previous topic :: View next topic

Author Message

GENTRYLL(at)aol.com
Guest

Posted: Mon Apr 09, 2007 2:48 pm Post subject: Trimming Acrylic Windshield

What is the best method to use for trimming an acrylic windshield as  furnished by LP Aero.



See what's free at AOL.com. 

  [quote][b]

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Mon Apr 09, 2007 3:24 pm Post subject: Trimming Acrylic Windshield

I used my Dremel tool with a #426 fiberglass-reinforced disc for the  

trimming. A saber saw would chip it as it cuts, and I recall that  

they frown on this. Finish the cuts by filing and then fine grade  

sandpaper, and round the edges slightly. No rough edges should remain.



Lynn

On Apr 9, 2007, at 6:46 PM, GENTRYLL(at)aol.com wrote:



 	  Quote: 	
		   What is the best method to use for trimming an acrylic windshield  

 as furnished by LP Aero.



 See what's free at AOL.com.

 www.matronics.com/Navigator?Kitfox-List _- 

 ============================================================

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

Float Flyr

Joined: 19 Jul 2006
Posts: 2704
Location: Campbellton, Newfoundland

Posted: Mon Apr 09, 2007 6:09 pm Post subject: Trimming Acrylic Windshield

I'd try a rotary spin saw... they don chip  at the glass and can produce a very clean edge.  Use the same saw to cut  composites.

  

  

 

Noel [quote]   

   --

_________________
Noel Loveys
Kitfox III-A
Aerocet 1100 Floats

Guy Buchanan

Joined: 16 Jul 2006
Posts: 1204
Location: Ramona, CA

Posted: Mon Apr 09, 2007 10:04 pm Post subject: Trimming Acrylic Windshield

At 03:46 PM 4/9/2007, you wrote:

  	  Quote: 	
		  What is the best method to use for trimming an acrylic windshield as furnished by LP Aero. 	


         I use a Dremel with their diamond disk. They're expensive but they last a long time. I cut about 1/16" off my mark. Make sure you cut against the rotation so the disk doesn't try to run across the plastic. Don't go slow because everything gets hot and heat's your enemy. (It causes thermal cracks.) 

         I then sand with 60 / 220 / 400. Make sure you use a board if you want straight edges. I then polish with TC6 (brown) and then PBC (blue) using the 1.5" cloth Dremel buffing disk. This leaves you with a transparent edge which is supposed to prevent cracks. 

          Just for information I drill small holes using plastic 0 rake angle drills and large holes using a Uni-bit. Be careful with the latter. Go slow and don't let it grab. De-burr the edges of any hole and polish the inside of the large holes using the small felt Dremel wheels and the above compuonds.



 Good luck!



 

 Guy Buchanan

 K-IV 1200 / 582-C / Warp / 100% done, thanks mostly to Bob Ducar.     [quote][b]

_________________
Guy Buchanan
Deceased K-IV 1200
A glider pilot too.

Fox5flyer
Guest

Posted: Tue Apr 10, 2007 3:08 am Post subject: Trimming Acrylic Windshield

I agree with Lynn.  You might also use an angle die grinder with an abrasive

disk.  It was recommended by LP and worked great for me.  Makita makes a

nice 1/4" model that is only about $60 or so.  With acrylics, stay away from

band saws.  It's very easy to crack the material.

Deke



---

Bob

Joined: 24 Oct 2006
Posts: 89
Location: Damascus, Maryland, USA

Posted: Tue Apr 10, 2007 4:40 am Post subject: Re: Trimming Acrylic Windshield

Lynn and Guy pretty well covered the cutting and dressing.  I'd just add that I use lots of wide masking or blue tape, both in front of the cut, and then behind it.  You don't want to put any stress on the plastic that you are about to cut, so every few inches, I'll stop and tape across the cut behind me.  If it's a big piece (like a windshield) I'll tape flat pieces of wood to bridge the cut on the front and back sides.

Bob

_________________
Remember that internet advice may only be worth what you pay.

n85ae

Joined: 14 Mar 2007
Posts: 403

Posted: Tue Apr 10, 2007 10:50 am Post subject: Re: Trimming Acrylic Windshield

I have a bi-metal blade in my big bandsaw, and I cut Lexan with it all the

time. Cuts it like butter, no chipping, and a simple attack on the edges with

a sanding block with some sandpaper knocks down the rough edges. I

cut one LP Bubble door with a dremel, the other with the bandsaw.  



Heck of a lot better than smelling melted acrylic from the dremel, 

and getting all that nasty grit all over yourself. The dremel, works ok

but if I had to do more than zero, I'll use the bandsaw any day. Practice

on the edge if you're scared. 



Could trim a bubble door in the time it took to type this, and probably a

better job than the dremel to boot.  



Jeff.

asq(at)roadrunner.com
Guest

Posted: Tue Apr 10, 2007 11:17 am Post subject: Trimming Acrylic Windshield

I agree. I have done a couple w/ the band saw and a fine blade and it worked 

very well. Not the one I broke,that was on installation. LPAero will also 

tell you how to grind your drill for drilling the holes.

                                                    Larry

---

n85ae

Joined: 14 Mar 2007
Posts: 403

Posted: Tue Apr 10, 2007 12:54 pm Post subject: Re: Trimming Acrylic Windshield

Actually when I first started building, I used to spend a lot of time

agonizing about things like this, which are really non-issues. Since I built

my Kitfox,  I also built an entire set of lexan storm windows for our house

and I feel like I've cut and drilled several miles of the stuff (exaggeration)

and I have NOT once cracked or splintered any of it. I have even worked

with the stuff in the winter. It's really simple. I use a step drill for drilling

most of the time, but also I have ground some regular bits. I made a little

camper trailer, and cut windows for it with the bandsaw as well. Never 

any trouble. 



I've read some many posts between this and the Zenith list over the years

you would think it's like working with fine crystal, but it's really not.   



Actually I think slipping with a dremel and scoring it, is MUCH more 

likely that the odds of wrecking a piece with a bandsaw.



Jeff

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Tue Apr 10, 2007 1:02 pm Post subject: Trimming Acrylic Windshield

I'd rather have that big $400 piece of acrylic resting comfortably on  

my workbench, and manipulate my small Dremel tool around it than the  

other way around.



To each his own.



Lynn

do not archive

On Apr 10, 2007, at 2:50 PM, n85ae wrote:



 	  Quote: 	
		   



 I have a bi-metal blade in my big bandsaw, and I cut Lexan with it  

 all the

 time. Cuts it like butter, no chipping, and a simple attack on the  

 edges with

 a sanding block with some sandpaper knocks down the rough edges. I

 cut one LP Bubble door with a dremel, the other with the bandsaw.



 Heck of a lot better than smelling melted acrylic from the dremel,

 and getting all that nasty grit all over yourself. The dremel,  

 works ok

 but if I had to do more than zero, I'll use the bandsaw any day.  

 Practice

 on the edge if you're scared.



 Could trim a bubble door in the time it took to type this, and  

 probably a

 better job than the dremel to boot.  



 Jeff.





 Read this topic online here:



 http://forums.matronics.com/viewtopic.php?p=106097#106097

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

lcfitt(at)sbcglobal.net
Guest

Posted: Tue Apr 10, 2007 3:39 pm Post subject: Trimming Acrylic Windshield

One thing no one has mentioned yet.  The AeroPlastics windsheld is Acrylic. 

It is an entirely different amimal than Lexan.  Acrylic will crack easily if 

not treated well.  Lexan on the other hand is used for break resistant 

glazing.  It has a rubbery consistency and will take a lot more abuse than 

Acrylic.  You can form it cold in a sheet metal brake.  Acrylic will break 

in a brake  and has to be heat bent usually with a hot wire.



Lowell



---

asq(at)roadrunner.com
Guest

Posted: Tue Apr 10, 2007 3:54 pm Post subject: Trimming Acrylic Windshield

One of you fellows is talking about polycarbonate and the other is talking 

about acrylic. BIG difference. You can cut polycarbonate with tin snips if 

you want to. It won't crack,but let a Dremel hog into a piece of acrylic(or 

a drill or anything else) and you will crack it. I have cut a fair amount of 

each. One of you said Lexan and acrylic in the same context Lexan is a brand 

name of polycarbonate. Plexiglas is a brand name for acrylic.

 Like plums and tangerines.  ;o)

  Not trying to start any arguments, just don't want someone to make an 

expensive mistake like some have before you.          Larry



---

GENTRYLL(at)aol.com
Guest

Posted: Tue Apr 10, 2007 4:03 pm Post subject: Trimming Acrylic Windshield

Now we are understanding the problem.  The original "glass" that comes  with a Kitfox kit is Lexan.  If you have to order a replacement from LP  Aero it will be acrylic.  I had 4 shipped to me before I received one that  UPS could not break.



See what's free at AOL.com. 

  [quote][b]

jdmcbean(at)cableone.net
Guest

Posted: Tue Apr 10, 2007 4:19 pm Post subject: Trimming Acrylic Windshield

Actually that would depend on which kit… The acrylic is what is supplied now with the kit..  We are also a distributor for LP and it doesn’t cost anymore.. sometimes can even save a little…  

<![if !supportEmptyParas]> <![endif]>  

 AUTOTEXTLIST \s "E-mail Signature" <![endif]-->Fly Safe !!  

John & Debra McBean  

208.337.5111  

www.kitfoxaircraft.com    

"It's not how Fast... It's how Fun!"  

<![endif]--><![if !supportEmptyParas]> <![endif]>  

-----Original Message-----

 From: owner-kitfox-list-server(at)matronics.com [mailto:owner-kitfox-list-server(at)matronics.com]On Behalf Of GENTRYLL(at)aol.com

 Sent: Tuesday, April 10, 2007 6:03 PM

 To: kitfox-list(at)matronics.com

 Subject: Re: Re: Trimming Acrylic Windshield  

<![if !supportEmptyParas]> <![endif]>  

Now we are understanding the problem.  The original "glass" that comes with a Kitfox kit is Lexan.  If you have to order a replacement from LP Aero it will be acrylic.  I had 4 shipped to me before I received one that UPS could not break.  

 <![if !supportLineBreakNewLine]> <![endif]>       

   

See what's free at AOL.com.   [quote]<![if !supportEmptyParas]> <![endif]><![if !supportEmptyParas]> <![endif]>          - The Kitfox-List Email Forum -   --> http://www.matronics.com/Navigator?Kitfox-List              - NEW MATRONICS WEB FORUMS -   --> http://forums.matronics.com<![if !supportEmptyParas]> <![endif]>[b]

asq(at)roadrunner.com
Guest

Posted: Tue Apr 10, 2007 4:58 pm Post subject: Trimming Acrylic Windshield

The older kits,model 4 did not use Lexan. They used Rhino. It  worked very well for me.          Larry

 [quote]   ---

GENTRYLL(at)aol.com
Guest

Posted: Tue Apr 10, 2007 5:12 pm Post subject: Trimming Acrylic Windshield

My kit was a 1992 and it had Lexan written on the paper. My  windshield  broke from the tight radius bend at the end of the spar on  top down a line at maximum curvature on both sides to the bottom.  In each  case it broke in the garage while I was in the back working on the header tank  behind the seat.  During  installation, I did not stress relieve with  heat as was later reccommended to me as it wasn't mentioned in the installation  instructions



See what's free at AOL.com. 

  [quote][b]

Float Flyr

Joined: 19 Jul 2006
Posts: 2704
Location: Campbellton, Newfoundland

Posted: Tue Apr 10, 2007 5:55 pm Post subject: Trimming Acrylic Windshield

I have to ask, Isn't  polycarbonate more sensitive to the effects of having gasoline dropped on  it?  Where gas will just drip off acrylic with little  damage?

  

  

 

Noel [quote]   

   --

_________________
Noel Loveys
Kitfox III-A
Aerocet 1100 Floats

asq(at)roadrunner.com
Guest

Posted: Tue Apr 10, 2007 6:08 pm Post subject: Trimming Acrylic Windshield

What ser # was yours? Mine is (I think) 1805. We must be  pretty close together. Sounds like whatever polycarbonate was available is what  was used. I stress relieved mine and it was in place about 2 yrs ago w/ 400 hrs  when it became so scratched and rough that I changed it. I found some Rhino  locally and used it again. Wonder if there is much difference?                                               Larry

 [quote]   ---

asq(at)roadrunner.com
Guest

Posted: Tue Apr 10, 2007 6:15 pm Post subject: Trimming Acrylic Windshield

That is correct. I have a white line down my right door window  where gas leaked from the tank drain while the door was latched  up.  That is the next replacement. Larry

 [quote]   ---

Fox5flyer
Guest

Posted: Wed Apr 11, 2007 3:40 am Post subject: Trimming Acrylic Windshield

I think whether it's Lexan or Rhino, it's still polycarbonate.  My  second windshield on my M2 was by Manchester, also polycarbonate.

 Deke

  

 [quote]   ---

Display posts from previous:

	Matronics Email Lists Forum Index -> Kitfox-List	All times are GMT - 8 Hours Goto page 1, 2 Next
Page 1 of 2

Jump to:

You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum
You cannot attach files in this forum
You can download files in this forum